Michael P. Belyansky

Characterization of wafer geometry and overlay error on silicon wafers with nonuniform stress

Abstract. Process-induced overlay errors are a growing problem in meeting the ever-tightening overlay requirements for integrated circuit production. Although uniform process-induced stress is easily corrected, nonuniform stress across the wafer is much more problematic, often resulting in noncorrectable overlay errors. Measurements of the wafer geometry of free, unchucked wafers give a powerful method for characterization of such nonuniform stress-induced wafer distortions. Wafer geometry data can be related to in-plane distortion of the wafer pulled flat by an exposure tool vacuum chuck, which in turn relates to overlay error. This paper will explore the relationship between wafer geometry and overlay error by the use of silicon test wafers with deliberate stress variations, i.e., engineered stress monitor (ESM) wafers. A process will be described that allows the creation of ESM wafers with nonuniform stress and includes many thousands of overlay targets for a detailed characterization of each wafer. Because the spatial character of the stress variation is easily changed, ESM wafers constitute a versatile platform for exploring nonuniform stress. We have fabricated ESM wafers of several different types, e.g., wafers where the center area has much higher stress than the outside area. Wafer geometry is measured with an optical metrology tool. After fabrication of the ESM wafers including alignment marks and first level overlay targets etched into the wafer, we expose a second level resist pattern designed to overlay with the etched targets. After resist patterning, relative overlay error is measured using standard optical methods. An innovative metric from the wafer geometry measurements is able to predict the process-induced overlay error. We conclude that appropriate wafer geometry measurements of in-process wafers have strong potential to characterize and reduce process-induced overlay errors.

High performance bulk planar 20nm CMOS technology for low power mobile applications

In this paper, we present a high performance planar 20nm CMOS bulk technology for low power mobile (LPM) computing applications featuring an advanced high-k metal gate (HKMG) process, strain engineering, 64nm metal pitch & ULK dielectrics. Compared with 28nm low power technology, it offers 0.55X density scaling and enables significant frequency improvement at lower standby power. Device drive current up to 2X 28nm at equivalent leakage is achieved through co-optimization of HKMG process and strain engineering. A fully functional, high-density (0.081um2 bit-cell) SRAM is reported with a corresponding Static Noise Margin (SNM) of 160mV at 0.9V. An advanced patterning and metallization scheme based on ULK dielectrics enables high density wiring with competitive R-C.

Stress Liner Effects for 32-nm SOI MOSFETs With HKMG

Strain effects from stress liners on silicon-on-insulator MOSFETs with high-k dielectric and metal gate (HKMG) are reported. By thoroughly evaluating their impact on drive current, mobility, and threshold voltage, the intrinsic performance gain of stress liners is quantified at the 32-nm node with mobility enhancement identified as the major source. It is also experimentally demonstrated that advantageous stress liners can reduce gate leakage currents for MOSFETs with HKMG.

Study of alternate hardmasks for extreme ultraviolet patterning

Traditional patterning stacks for deep ultraviolet patterning have been based on a trilayer scheme with an organic planarizing layer, silicon antireflective coating or organic bottom antireflective coating, and photoresist. At an extreme ultraviolet (EUV) wavelength, there is no longer a need for reflectivity control. This offers an opportunity to look at different types of underlayers for patterning at sub-36 nm pitch length scales. An alternate hardmask can be used to develop a low aspect ratio patterning stack that can enable a larger process window at sub-36 nm pitch resolution. The hardmask layer under the resist has the potential for secondary electron generation at the resist/hardmask interface to improve resist sensitivity. This work explores EUV patterning on deposited hardmasks of various types such as silicon oxides and metal hardmasks. It also details the challenges of patterning directly on an alternate underlayer and approaches for improving patterning performance on such layers.

Technologies for scaling vertical transistor DRAM cells to 70 nm

Vertical transistor DRAM cells have been demonstrated as viable in the 110 nm generation. This paper describes the issues associated with scaling these cells to the 70 nm node and demonstrates fixes to all known issues. Scaling to 70 nm is possible through the development of two key enabling technologies, high aspect ratio STI fill and low resistance metal deep trench fill, and through minor cell modification. Each of these items are addressed and shown to be viable using a functional 512 Mb prototype DRAM chip at 110 nm half-pitch groundrule. Based on these results, we believe the vertical transistor DRAM cell is one of the most promising for continued scaling of conventional DRAM and embedded DRAM cells.

Characterization and mitigation of overlay error on silicon wafers with nonuniform stress

Process-induced overlay errors are a growing problem in meeting the ever-tightening overlay requirements for integrated circuit production. While uniform process-induced stress is easily corrected, non-uniform stress across the wafer is much more problematic, often resulting in non-correctable overlay errors. Measurements of the wafer geometry of free, unchucked wafers give a powerful method for characterization of such non-uniform stress. We will describe a Patterned Wafer Geometry (PWG) tool, which uses optical methods to measure the geometry of in-process wafers. PWG data can be related to In-Plane Distortion (IPD) of the wafer through the PIR (Predicted IPD Residual) metric. This paper will explore the relationship between the PIR data and measured overlay data on Engineered Stress Monitor (ESM) wafers containing various designed stress variations. The process used to fabricate ESM wafers is quite versatile and can mimic many different stress variation signatures. For this study, ESM wafers were built with strong across-wafer stress variation and another ESM wafer set was built with strong intrafield stress variation. IPD was extensively characterized in two different ways: using standard overlay error metrology and using PWG metrology. Strong correlation is observed between these two independent sets of data, indicating that the PIR metric is able to clearly see wafer distortions. We have taken another step forward by using PIR data from the PWG tool to correct process-induced overlay error by feedforward to the exposure tool, a novel method that we call PWG-FF. We conclude that appropriate wafer geometry measurements of in-process wafers have strong potential to characterize and reduce process-induced overlay errors.

Thin-Film Strain Engineering and Pattern Effects in Dielectrics CVD

This chapter covers two different topics which have become increasingly important in the semiconductor industry due to shrinking device dimensions and continuation of scaling: (a) effect of intrinsic film stress on a semiconductor device and (b) interaction of chemical vapor deposition (CVD) with pattern density. This chapter surveys new developments in deposition of highly strained dielectric thin films and evolution in film properties, especially in film intrinsic stress. The basics of silicon strain engineering as well as silicon strain metrology are covered.